Method of staining and filling wood



2,805,759 Patented Sept. 17, 1957 Chadeloid Corporation, Dayton, ()hio, a corporation of Delaware No Drawing. Original application .lune 16, 195%, Serial No. 168,664, now Patent No. 2,674,533, dated April 6, 1954. Divided and this application October 14, 1952, Serial No. 314,739

7 Claims. (Cl. 8-6.5)

This invention relates to wood finishing. More particularly, it relates to a method of staining and filling Wood. Still more particularly, it relates to compositions which are adaptable to perform one or more of the functions of filling the pores and staining the wood preparatory to application of finish coatings.

The conventional fillers suffer from many disadvantages. After most of the fillers are applied the wood surface must be dried for at least 12 hours before the surface can be sanded and a sanding sealer applied.

Another disadvantage is the softening of the filler coat by solvents contained in the overlaid lacquer coats, which results in a tendency for the coating to suck-in the wood pores upon drying.

Another disadvantage of prior commercial stain fillers is that an oil vehicle is utilized. This oil is deposited on the surface of the wood in a thin film which does not dry readily. This film is still present when the lacquer is applied and tends to retard the drying and softens the lacquer film, which in turn slows down finishing operations.

It is an object of the present invention to overcome the disadvantages and difiiculties associated with the above described stain fillers.

It is another object of the present invention to provide neutral filler compositions which seal the wood pores, thereby eliminating the necessity for a sanding sealer.

It is a further object of this invention to produce a neutral filler paste which may be converted to a stain filler by addition of dye solution whose solvents are compatible with solvents in the paste.

It is a further object of this invention to produce a filler or a stain filler that is not readily softened by solvents and thinners contained in overlaid coatings.

It is still another object to provide a stain filler whose wood pore fillings do not have a tendency to shrink and to suck-in upon drying.

A still further object of this invention is to produce a stain filler with a markedly reduced tendency toward retention of solvents in the filling, a tendency which causes pin-holing in lacquer films overlaying such filler material.

A further object of this invention is to provide a stain filler having a new combination of vehicles which deposits a tough hard mass in the wood pores which is not greatly affected when lacquer comes in contact there- .with.

. rosin free, an alcohol solvent for said shellac, a natural gum for use as drying modifier and inert filler.

Shellac, as binder for the inerts and other components, exhibits excellent air drying, which is so essential to a stain filler. However, alone shellac is too fast drying. To modify the drying characteristic of shellac which impairs the wiping qualities of the coating composition, it is necessary to add small amounts of fossil or semi-fossil type gums.

The modifying gums are generally added as a high solids content butanol solution. Useful gums of this type are Batu, Congo elemi, kauri, mastic, Pontianak, Manila, sandarac, and the like.

Solvents useful in this composition which have solvent power for shellac and gum as well as for the acid dyestuffs are the Carbitols, for example, diethylene glycol monoethyl ether, monobutyl ether, the Cellosolves such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, monobutyl ether, tetrahydrafurfuryl alcohol, and equivalent alcohols.

Additional solvents useful in various solvent combinations are, the alkyl alcohols such as ethyl, propyl and butyl alcohols, the amino alcohols, such as methyl amino propanol, ethyl amino butanol, cyclic alcohols such as furfuryl alcohol, cyclohexanol in mixture with each other or in mixtures with volatile alcohols.

These volatile alcohols are usually added in the form of a thinner mixture often composed of aromatic hydro carbon, such as toluol, xylol, aromatic naphthas and alcohol, but more often consisting simply of aliphatic alcohols, such as ethanol, propanol, butanol, amyl alcohol, and so forth. A minor proportion of esters of said aliphatic alcohols, such as ethyl acetate, propyl acetate and the like, may sometimes be added to the thinner.

To convert the neutral filler paste to a stain filler, there need merely be added a concentrated dye solution, the solvent for the dye being compatible with the alcohol solvent for the shellac.

The preferred solvent for dye solution is a Carbitol such as was mentioned hereinbefore or .a mixture of a Carbitol with a Cellosolve, for example, diethylene glycol monomethyl ether and ethylene glycol monomethyl ether.

All acid organic dyestuffs are operative for the process and the pro-duct of this invention. Thus, for example, the following dyestuffs may be utilized: Buffalo Black NBR Conc. 126%, Black Stain B34951, Nigrosine 4523] Conc. Powder; the following yellow dyestuffs: Fast Wool Yellow 3GL Conc. Fast Light Yellow 3G Ex. Conc., Fast Light Yellow D3GA; the following orange-yellow dyestufls; Metanil Yellow 1955, Calcocid Yellow MXXX Conc.; the following orange dyestuffs; Fast Light Orange 2G, Fast Light Orange GA Conc.; the following red dyestufis: Azo Rubine Ex. Conc. 133%, Calcocid Milling Red 7B Conc., Carmoisine BA Extra Conc. C.F., Chromolan Bordeaux R. Croceine Scarlet M00.

As filler materials, the following substances were found to be operative; silene, which is a hydrated precipitated calcium silicate; silex, which is a silica; calcium carbonate; diatomaceous earth, bentonite; asbestine; clay; talc; and the like.

Certain of the fillers, such as silene and silex, are preferred because they can be used without darkening pigments and thereby impart a clearness and transparency to the coating composition. Further, they enhance the natural brillance of the Wood.

The separate neutral paste and dye compositions of this invention are prepared by simply mixing the ingredients together. Preferably the dye or dyes are prewetted with methanol, butanol, or a glycol ether, in an agitator, such as a pony mixer.

To the wetted dye mixture is added a solvent such as diethylene glycol monoethyl ether and the mixture agitated until all the dye is dissolved.

A neutral paste composition is prepared by first dissolving :shellac .in, for example, butanol, and secondly V dissolving a desired-quantity of gum in butanol. The solutions are mixed and then lastly the fillers are added. If a stain filler is desired, the neutralpaste and .dye solution are mixed together as in a pony mixer. 'The mixing method providesa simple andinexpensive method of manufacture, saves grinding time, and eliminates the use'of expensive ball mills.

After thorough mixing, the composition is ready to be diluted to the desired consistency for brushing orspraying onto a wood surface.

'After the neutral filler or the .stain filler has been applied to the wood, the excess material is removed by padding or wiping which is standard stain vfiller practice. 7 The stain filler composition of this invention may be air .dried in approximately eight minutes after wiping and then sprayed with lacguer. The lacquer coat is .dried130 to ,60 minutes as desired before sanding and finishing to suit the operator. 7 a

Operations with;the compositions of this invention may be speeded up by force drying. For example, the stain filler may be force dried 'forfive minutes at 120 to 140 F. immediately after ;it is wiped. 'It is then cooled .forat leastfive minutes .before applying a, sealer coat. .After sanding thedry sealer coat the :lacquercoat mayibeapplieda V The lacquer coat is.air.dried.for a periodof .four to five .minutes .andthe coated-wood returned to the same -oven forv approximately ten minutes. Upon its removal fromthe oven ,it iscooled for at least five minutes before sanding and then applying the next lacquer :coat.

By useof force-drying throughout'theentire finishing process, the rubbing operation with rotten stone, oil, pumice, or other .types of. rubbing compounds, may be performed 30 minutes'after drying of final lacquer coat.

The quantities of basic constituents may be-varied within-reasonable limits depending upon the specific formulati on desired. In general, itrmay be stated-that'a-formu- 'lation including ethylene glycol monomethyl ether may "have-the ether and any companion alcohols which form a dye solvent vary from 5 to 50 parts by weight of the alcohol, and 5 to 100 parts by weight of ethylene glycol monomethyl ether.

In formulation involving diethylene glycol mono- 'methyl ether, the ether may be varied from 1 to 100 parts, and where tetrahydrafurfuryl alcohol is utilized instead of a vCarb'itol or a Cellosolve, it may 'be varied fr'om.51to 100jparts.

Thedye may constitute from 1 to 50 parts or more of the dye-solvent solution, depending upon the amount of inerts which will be added at a later step.

The shellac which is normally used in the form of a 50% alcohol solution may be varied from 5 to 100 parts .itmay be stated that the inerts may. vary from .to :100 parts by weight.

When a thinner mixture madeup of toluol, and which includes high fiash naphtha (a coal tar derivative) and butanol, the'butanol may constitute 5 to 75 parts of themixture. The toluol and naphtha may be varied from 5 to 50 parts byweight.

In general, it is preferred'to use a mixture of which toluol constitutes at least 50%. 7

In the following examples a few embodiments of 'the invention are illustrated, without intending thereby to limit the invention thereto:

A typical example of a neutral filler composition comprising shellac is:

372 gms. (550 cc.) butanol 685.0 gms., 50% refined shellac wax and rosin free cen- In preparingthis neutral filler,shellac-alcoholsolution is poured into a pony mixer. The shellac solution is thinned by addition of the butanol.

After 5 minutes stirring the Manilaggumbutanol solution is added and the combination stirred .for .2 minutes. The inert filler is then added-with preferably the silica being added first.

In making a stain filler, there is added to the above neutral filler about 3 to 10% of .adye concentrate.

'Dye concentrates for this purpose may comprise jthe following concentrates which are designatedior' convenience, A, B, and C:

Dye concentrate .black .(A):

16 gms. Bufialo .Black :NBR-l26% 22 gms. methyl carbitol 113 gms. methyl cellosolve Dye concentrate scarlet (BJ 16 gms. azo rubine dye 22 gms. methyl carbitol 113 gms. methyl cellosolve Dye concentrate orange (C):

16 gms. Orange ZYA 22 gms. methyl carbitol 113 gms. methyl cellosolve.

For preparing, for example, .a red mahogany stain fill- ,er, various proportionsof neutral filler -(1) and dye concentrates (A), (B) and (C) may be combined depending .upon the type of wood .to be treated and .the depth ;of,color sought.

vA typical compostion comprises: a

gms. of neutral filler (l) 1 gm. of dye concentrate (A) 6.5 gms. of dye concentrate (B) 7.5 gms. of dye concentrate (C) This concentrated stain filler may :be prepared .for use by thinning 8 to 10 lbs. of the-mixture with '1. gallon of solvent thinner or diluents.

A typical stain filler ready for spraying will have the following composition:

185 gms. stain filler paste 7 15 gms. dye concentrates .90 cc. 'butanol -60 cc. toluol 50cc. high flash naphtha (coal tar derivative) It will, of course, be understood that the color concentrates are not limited to black, scarlet and orange. Other concentrates such as brown, yellow, purple, and lthelike, may be prepared for blending to meetany desired shading.

The thinner composition is also subject to. considerable variation. 'Butanol may constitute 20-50% of the thinner, while toluol and high flash naphtha vareusually maintained in a ratio of 1 of 'toluol'to 1 to 1.6 of naphtha.

It will be understood that while there have been given herein specific examples of the practice of this inven- 'tion, it is not intended thereby to have this invention limited to or circumscribed by the specific details-ofmaterials, proportions, or conditions herein specified, 'in'view of the fact that this-invention may be modified according to individual preference or conditions without. necessarily departing from the spirit of thisdisclosure and the scope of the appended claims.

This application is a division of my copending application, Serial No. 168,664, new Patent No. 2,674,538.

I claim:

1. In a method of coating and filling wood in a single operation, the steps of applying a solution-suspension consisting of a solvent characterized by the presence of hydroxyl group, acid organic dyestufif, inert filler, shellac, a fossil type gum; and mechanically removing any excess material after a predetermined period of contact with the Wood, said fossil gum comprising -20% by weight of said shellac.

2. In a method of coating and filling wood in a single operation, the steps of applying a solution-suspension consisting of a solvent characterized by the presence of hydroxyl group, acid organic dyestuff, inert filler, pigment, shellac, 10 to 20% by weight of the shellac of Manila gum, a thinner mixture consisting of 20 to 30% toluol, 20 to 30% high flash naphtha and 30 to 60% butanol; and mechanically removing any excess material after a predetermined period of contact with the wood.

3. In a method of coating and filling wood in a single operation, the steps of applying a solution-suspension consisting of a solvent base mixture characterized by the presence of hydroxyl group, acid organic dyestufi, inert filler, pigment, shellac, Manila gum; and mechanically removing any excess material after a predetermined period of contact with the wood, said Manila gum comprising 10-20% by weight of said shellac.

4. In a method of coating and filling wood in a single operation, the steps of applying a solution-suspension consisting of at least one solvent selected from the group of diethylene glycol monoalkyl ether, ethylene glycol monoalkyl ether, ethanol, butanol and tetrahydrofurfuryl alcohol; acid organic dyestufi; inert filler; pigment; shellac and fossil type gum; thinned with a solvent mixture consisting of toluol, high flash coal tar naphtha and butanol; and mechanically removing any excess material after a predetermined period of contact with the wood, said fossil gum comprising 10-20% by weight of said shellac.

5. In a method of coating and filling Wood in a single operation, the steps of applying a solution-suspension consisting of a solvent mixture of 5 to 100 parts ethylene 6 glycol monomethyl ether; 1 to parts acid organic dye; 5 to 100 parts shellac; 1 to 10 parts fossil gum; 5 to 50 parts polyvinyl alcohol; 10 to 100 parts inert filler; l to 20 parts dispersing agent; thinned the resultant mixture with a solvent comprising 5 to 50 parts by weight of toluol; 5 to 50 parts by weight of high flash naphtha; 5 to parts butanol; and mechanically removing any excess material after a predetermined period of contact with the wood, said fossil gum comprising at least 10- 20% by Weight of said shellac.

6. In a method of coating and filling wood in a single operation, the steps of applying a solution-suspension consisting of a solvent mixture of 5 to parts ethylene glycol monomethyl ether; 1 to 50 parts acid organic dye; 5 to 100 parts shellac; 1 to 10 parts Manila gum; 5 to 50 parts polyvinyl alcohol; 10 to 100 parts inert filler; l to 20 parts dispersing agent; thinned with a solvent comprising 5 to 50 parts by Weight of toluol; 5 to 50 parts by weight of high flash naphtha; 5 to 75 parts butanol; and mechanically removing any excess material after a predetermined period of contact with the Wood, said Manila gum comprising at least 10-20% by weight of said shellac.

7. In a method of coating and filling wood in a single operation, the steps of applying a solution-suspension consisting of a solvent mixture of 17.6 gms. butanol, 15.6 gms. shellac, 15.6 gms. ethanol, .6 gm. Manila gum, 95.6 gms. silica, 40 gms. talc., gms. neutral stain filler, 1.28 gms. scarlet dye, .32 gm. black dye, 2.15 gms. diethylene glycol monomethyl ether, 11.25 gms. ethylene glycol monomethyl ether; thinned with a solvent comprising 90 cc. butanol, 60 cc. toluol, and 50 cc. high flash naphtha; and mechanically removing any excess material after a predetermined period of contact with the Wood.

References Cited in the file of this patent UNITED STATES PATENTS 2,565,602 Fisher Aug. 28, 1951 2,623,027 Deniston Dec. 23, 1952 2,628,206 Deniston Feb. 10, 1953 2,632,710 Mayers Mar. 24, 1953 

1. IN A METHOD OF COATING AND FILLING WOOD IN A SINGLE OPERATION, THE STEPS OF APPLYING A SOLUTION-SUSPENSION CONSISTING OF A SOLVENT CHARACTERIZED BY THE PRESENCE OF A FOSSUL TYPE GUM; AND MECHANICALLY REMOVING ANY EXCESS METERIAL AFTER A PREDETERMINED PERIOD OF CONTACT WITH THE WOOD, SAID FOSSIL GUM COMPRISING 10-20% BY WEIGHT SAID SHELLACE. 